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  Fire resistant barrierUSPTO Application #: 20070175649Title: Fire resistant barrier Abstract: A fire resistant assembly, which may comprise a first layer having a lumen therein, a second layer adjacent the first layer, a first structural member disposed between the first and second layers, and a box having a cavity defined by a wall, a first opening in the wall, a flange proximate the first opening, and optionally a second opening in the wall, wherein the box is disposed between the first layer and the second layer and wherein the opening is disposed on the lumen of the first layer, the box comprising a further fire resistant feature such as an intumescent ring disposed about the second opening, a plenum wrap layer, or an intumescent layer, and various methods and apparatuses related thereto. (end of abstract)
Agent: Crompton, Seager & Tufte, LLC - Minneapolis, MN, US Inventor: Happy Moselle USPTO Applicaton #: 20070175649 - Class: 174050000 (USPTO) Related Patent Categories: Electricity: Conductors And Insulators, Boxes And Housings The Patent Description & Claims data below is from USPTO Patent Application 20070175649. Brief Patent Description - Full Patent Description - Patent Application Claims
FIELD OF THE INVENTION [0001] The invention relates to a fire barrier having a recess for a device. More particularly, the invention relates to a recessed box installed in a building for use with maintaining a minimum fire endurance of a building surface. BACKGROUND OF THE INVENTION [0002] Typically, a surface of a building such as a floor, a ceiling between levels, or a ceiling under an attic provides a fire barrier. A fire barrier resists the spread of a fire through it by providing a resistance to flammability, a resistance to heat transmission, and sufficient structural integrity to resist decomposing when exposed to heat or flames. The effectiveness of a fire barrier is often rated by exposure to a fire of specified and increasing intensity and a rating is a period of time, typically in hours during which the fire barrier is effective. When an aperture is made in one of these fire barriers, the effectiveness of the fire barrier is decreased dramatically. Often it is nonetheless desirable to create an aperture in a fire barrier, for example, to install recessed lighting or a floor drain. To restore the fire barrier and maintain an effective minimum resistance to fire, a construction worker will typically build a box of gypsum board and install it around the recessed fixture proximate the aperture created in the fire barrier. The construction of this box is a time consuming task and provides no mechanism to ascertain to what degree the effectiveness of the fire barrier is restored. Moreover, many fixtures have large conduits such as pipes or cable servicing them. Constructing a box that provides egress for these conduits while maintaining integrity as a fire barrier is often a time-consuming and chancy process. Also, many fire barrier boxes constructed at the job site may prove inadequate for applications requiring extended fire ratings, such as two hours or more. SUMMARY OF THE INVENTION [0003] One embodiment pertains to a box for maintaining the integrity of a fire barrier in a building while permitting the installation of a recessed fixture such as a light, an exhaust fan, or a speaker. The box may be made from steel or other suitable material and may optionally have a flange for convenient mounting to structural members such as ceiling joists, wall studs or floor trusses. The box has a first opening through which the fixture may be mounted and a second opening which provides access to provide service to the fixture. For example, the second opening may be sized to provide access to electrical conduit. Surrounding the second opening is an intumescent material such as an intumescent ring. [0004] Another embodiment pertains to another box for maintaining the integrity of a fire barrier while permitting the installation of a recessed fixture. This box has a first layer made of steel or other suitable material and a second layer which is made from a plenum wrap or other similar material. The second layer may be spaced apart from the first layer to provide an additional thermal barrier and may be provided inside or outside the first layer. The box has a first opening through which a fixture may be mounted and may have a second opening. [0005] Another embodiment pertains to another box for maintaining the integrity of a fire barrier. This box may be made from steel or other suitable material and may have a flange to provide means for convenient mounting to a structural member. The box includes an intumescent layer or wrap. [0006] Another embodiment pertains to a fire barrier including a box such as one of those described above. The fire barrier is typically a building member such as a wall or an attic ceiling. The building member includes two planar surfaces with structural members disposed therebetween. The box is attached, such as by the flange, to one or two of the structural members such that one side of the box is flush with one of the planar surfaces and the opposite side of the box is at least a predetermined distance from the other planar surface. A hole may be provided in the former planar surface where the first opening of the box is and a fixture may be installed therein. The box may be rated to have a 2 hour fire endurance rating under ASTM E-119 or other comparable test and certification of the rating may be found with or on the box [0007] In certain embodiments, an intumescent material such as an intumescent foam or other suitable intumescent material may be used with the box. Such a material can provide a material sound deadening quality so the box can be installed in a fire barrier so the fire barrier has a sound transmission rating. [0008] The above summary of some embodiments is not intended to describe each disclosed embodiment or every implementation of the present invention. The figures and detailed description which follow more particularly exemplify these embodiments. BRIEF DESCRIPTION OF THE DRAWINGS [0009] The invention may be more completely understood in consideration of the following detailed description of various embodiments of the invention in connection with the accompanying drawings in which: [0010] FIG. 1 is a perspective diagrammatic view of a box 100 for providing fire resistance according to the invention; [0011] FIG. 2 is a cross sectional diagrammatic view of box 100 positioned inside a fire barrier 200; [0012] FIG. 3 is a cross sectional diagrammatic view of a box 300 for providing fire resistance according to the invention; and [0013] FIG. 4 is a cross-sectional diagrammatic view of a box 400 for providing fire resistance according to the invention. DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS [0014] Reference is now made to the figures, in which like element numbers refer to like elements throughout. FIG. 1 is a perspective view of a box 100, which includes a wall 104 defining cavity 102. Opening 106 provides access to cavity 102 and flange 108 is disposed proximate opening 106. It is to be understood that, while wall 104 is shown in FIG. 1 to be comprised of five flat surfaces and the opening, any shape defined by a cavity and having an opening may be suitable. For example, a cylinder open at one end may be suitable. [0015] Flange 108 may be comprised of one or more individual pieces 110 and generally defines a flat surface 112 facing away from cavity 102. Flange 108 is shown as comprising a lip extending a uniform distance away from the edge of the opening. It is to be understood however, that many more configurations that may be suitable are contemplated. For example, flange 108 may have struts which extend over the opening to provide means for attaching a device such as a light fixture. In addition, flange 108 may have wings that extend from the opening to provide additional means for attaching the box in the fire barrier. Flange 108 may include means for attaching box 100 to a structural member such as lumens 114 for receiving nails or screws. [0016] Wall 104 may include an additional opening 116 for providing service to a fixture installed in cavity 102. Opening 116 may surrounded by an intumescent ring 118. An intumescent material is one that expands when in contact with fire or high heat but resists further deterioration. Many intumescent materials expand to eight or more times their original volume, producing a char which has a high fire resistance. Intumescent ring 118 may be a pre-molded ring installed into opening 118 or may be a paint or mastic applied around opening 116 or may be another suitable intumescent material. Intumescent ring 118 is configured to seal opening 116, sealing around any conduit installed therethrough, when exposed to fire or heat. [0017] Alternatively, wall 104 may include one or more punch-outs 120 that permit ready removal with a hammer or screwdriver for created additional openings to the cavity. Punch-outs 116 generally comprises one or more grooves of reduced wall thickness formed in a closed pattern. Punch-outs 120 may be of several shapes and sizes to allow for the creation of additional openings adapted to specific tasks or in convenient locations. In this embodiment, intumescent ring 118 may be a putty installed around the opening 116 created by the removal of the punch-out. [0018] Refer to FIG. 2, which is a cross sectional view of box 100 disposed in a fire barrier 200, which is fire resistant and has a device 232 disposed therein. [0019] The term "fire resistant" is herein defined to refer to the ability of a structure to serve as a barrier to the spread of fire. To serve as an effective barrier to the spread of fire, a structure must exhibit the following characteristics. First, it must not pass flame or hot gas from one side to the other. Second, the structure must support the imposed design loads without structural failure or collapse. Third, the structure must resist the transmission of heat so that the surface not exposed to the fire does not exceed the temperature of 250.degree. F. Fourth, the structure must withstand lateral impacts from falling debris. This is definition of the term "fire resistant" as understood by those of skill in the art. Continue reading... Full patent description for Fire resistant barrier Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Fire resistant barrier patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. 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